Customization of amorphous alloy transformer

　　Key Points for Customization of Amorphous Alloy Transformers

　　I. Core Advantages and Necessity of Customization

　　Amorphous alloy transformers utilize iron-based amorphous metallic cores, characterized by disordered atomic arrangements that significantly outperform traditional silicon steel in magnetization and demagnetization processes. This property reduces no-load losses by 70%-80% compared to conventional transformers, enabling annual electricity savings of 25-30 TWh and CO₂ emission reductions of 20-30 million tons when deployed across distribution networks. Customized production allows optimization for varying voltage levels (e.g., 10 kV, 35 kV), capacity requirements (100 kVA–3,150 kVA), and installation environments (indoor/outdoor, extreme climates), balancing performance and cost-efficiency.

　　II. Customization Process and Key Parameters

　　1. Requirement Confirmation

　　Specify foundational parameters such as voltage combinations (e.g., 10 kV/0.4 kV), rated capacity (e.g., 1,000 kVA), phase configuration (three-phase/single-phase), and winding connection groups (e.g., Dyn11).

　　Define application scenarios (industrial power supply, building distribution, or rural grid upgrades) to align with diverse load characteristics.

　　2. Core Design

　　Material Selection: Use iron-based amorphous alloy strips (0.03 mm thick), subjected to annealing to eliminate internal stress and ensure low-loss performance.

　　Structural Optimization: Prioritize four-frame five-limb wound core structures with independent magnetic circuit designs to eliminate third-harmonic flux and reduce additional losses.

　　Magnetic Flux Density Control: Recommend a rated flux density of 1.3–1.35 T to prevent loss escalation due to the material’s lower saturation flux density.

　　3. Winding and Tank Design

　　Winding Configuration: Adopt rectangular-section double-layer or multi-layer rectangular layer windings to minimize cutting waste and improve filling coefficients.

　　Tank Structure: Implement fully sealed corrugated tanks for maintenance-free operation in harsh outdoor environments.

　　4. Protection Function Customization

　　Integrate overload protection, short-circuit protection, and temperature monitoring modules for safe operation. For example, the SCBH15 series dry-type transformers achieve long-term operation at 150% rated load via forced air cooling systems.

　III. Representative Customization Case Studies

　　1. Jiangsu Juli Electric Power Equipment Co., Ltd.

　　Product Model: SH15-1000KVA Amorphous Alloy Oil-Immersed Transformer

　　Custom Options:

　　Voltage combinations: 10 kV/0.4 kV (expandable to 35 kV/10 kV)

　　Capacity range: 100 kVA–2,500 kVA

　　Special designs: Fully sealed structure, corrugated tank, automatic protection functions

　　Performance Metrics: 70% reduction in no-load loss versus GB/T6541 standards; noise levels below 65 dB (compliant with European environmental regulations).

　　2. Zhejiang Guanlai Electric Co., Ltd.

　　Product Model: S22-M-RL Three-Phase Amorphous Alloy Transformer with Stereoscopic Wound Core

　　Custom Highlights:

　　Stereoscopic wound core structure reducing no-load loss by 15%

　　Support for customization for high-altitude and high-overload environments

　　Multiple winding connection options (Dyn11, Yyn0, etc.)

　　IV. Customization Considerations

　　Process Coefficient Control: Maintain a core assembly process coefficient of 1.08–1.15 to compensate for loss increases from joint processing.

　　Mechanical Stress Avoidance: Since amorphous alloys are sensitive to mechanical stress, avoid using the core as the primary load-bearing structure; adopt independent support frames instead.

　　Cost Optimization: Reduce non-standard components by 10%-15% through modular designs, such as standardized tank dimensions and universal winding molds.